Fabric printing method for producing sparkling fabric

ABSTRACT

A sparkling fabric includes: a fabric substrate; and a tri-layer adhered to the fabric substrate. The tri-layer includes: an adhesive layer that adheres the tri-layer to the fabric substrate; an exposed design layer; and a metal plating layer between the exposed design layer and the adhesive layer. The tri-layer is distributed as a plurality of separable and identifiable tri-layer pieces across the fabric substrate such that the distribution of tri-layer pieces has a density on the order of 15-25 pieces per centimeter squared (pcs/cm2) and a size of a piece is less than 1 millimeter (mm).

CROSS REFERENCE TO RELATED APPLICATION

This application is a divisional and claims the benefit of U.S.application Ser. No. 16/460,512, filed Jul. 2, 2019 and titled FABRICPRINTING METHOD FOR PRODUCING SPARKLING FABRIC, which claimed thebenefit of U.S. Application No. 62/694,708, filed Jul. 6, 2018 andtitled FABRIC PRINTING METHOD FOR PRODUCING SPARKLING FABRIC. Both ofthese patent applications are incorporated herein by reference in theirentirety.

TECHNICAL FIELD

This disclosure relates to a method of making a sparkling fabric and thesparkling fabric.

BACKGROUND

Prior techniques for creating fabric that sparkles use glitter, whichcan be applied or sprayed to the fabric to achieve sparkling effect.Glitter is made of an assortment of separate and identifiable reflectiveparticles. The assortment is such that the particles reflect light atdifferent angles. At least one flat surface of the particles isreflective and this surface has an extent that is fairly small and canbe sub-millimeter (mm) in size. Typically, a particle of glitter hasseveral layers, including a base layer onto which a reflective materialsuch as aluminum is applied.

SUMMARY

In some general aspects, a fabric printing method includes: applyingadhesive to a sparkling foil paper to form an adhesive base paper,pressing the adhesive base paper to a fabric to form a fabric laminate,cooling the fabric laminate until the adhesive dries, and removing thesparking foil paper from the fabric of the fabric laminate. The adhesiveis applied to the sparkling foil paper by distributing the adhesive as aplurality of separable and identifiable adhesive pieces over an outerlayer of the sparkling foil paper such that the distribution of pieceshas a density on the order of 15-25 pieces per centimeter squared(pcs/cm2) and a size of a piece is less than 1 millimeter (mm). Theadhesive base paper is pressed to the fabric by contacting the side ofthe adhesive base paper to which the adhesive has been applied with thefabric while maintaining the temperature of the adhesive above a meltingpoint of the adhesive. The sparking foil paper is removed from thefabric of the fabric laminate such that the distribution of adhesive andthe outer layer of the sparkling foil paper to which adhesive has beenapplied remain attached to the fabric in accordance with the adhesivedistribution to thereby form a sparkling fabric.

Implementations can include one or more of the following features. Forexample, the method can also include receiving the sparkling foil paper,and the sparkling foil paper can include a design layer including aplurality of two-dimensional geometric forms, with a size of each of thegeometric forms being larger than the largest size of the adhesivepieces and a density of the geometric forms being greater than thedensity of the distribution of adhesive pieces. The geometric form canbe a circle, dot, or polygon such as a hexagon, or any combination ofthese shapes. The size of the geometric forms in the design layer of thesparkling foil paper can be about 1.5 mm or between about 1.0-2.0 mm,and the density of the geometric forms in the design layer of thesparkling foil paper can be about 70-80 pcs/cm². The design layer can bean embossed layer. The design layer can be a layer of geometric formshaving a plurality of different colors.

The sparkling foil paper can be a multi-layer paper.

The distribution of pieces on the sparkling fabric can include adistribution of at least three different sizes of pieces as follows: aplurality of small-sized pieces, distributed in accordance with ahighest density; a plurality of medium-sized pieces, distributed inaccordance with a middle density; and a plurality of large-sized pieces,distributed in accordance with a lowest density. The highest density ofthe small-sized pieces can be about 9-12 pcs/cm²; the middle density ofthe medium-sized pieces can be about 8-9 pcs/cm²; and the lowest densityof the large-sized pieces can be about 3-5 pcs/cm². The large-sizedpieces on the sparkling fabric can have a geometric shape in the planeof the sparkling fabric that is distinct from a geometric shape of atleast the small-sized pieces and the medium-sized pieces.

At least some of the pieces in the distribution of pieces on thesparkling fabric can have a geometric shape in the plane of thesparkling fabric that is distinct from a geometric shape of the otherpieces in the distribution of pieces on the sparkling fabric.

The temperature of the environment of the adhesive base paper and thefabric while pressing the adhesive base paper to the fabric can bemaintained above 140° C.

The fabric laminate can be cooled until the adhesive dries by storingthe fabric laminate in at a temperature of about 60° C. to 80° C.environment for at least 12 hours.

The fabric can be made of satin.

The adhesive can be applied to the sparkling foil paper to form theadhesive base paper by applying the adhesive so that the adhesive coversabout 30% of the outer layer of the sparkling foil paper.

The fabric printing method lacks an application of glitter to thefabric.

The adhesive can be made of 50% adhesive, 40% butanone, and 10% curingagent, by weight.

The adhesive can be applied to the sparkling foil paper by distributingthe plurality of separable and identifiable adhesive pieces as a singlelayer over the outer layer of the sparkling foil paper.

The adhesive can be applied to the sparkling foil paper to form theadhesive base paper by: applying the adhesive to an embossing cylinderhaving a surface topography that is correlated with the distribution ofadhesive that is applied to the outer layer of the sparkling foil paperto form a prepared embossing cylinder; and pressing the sparkling foilpaper to the prepared embossing cylinder as the prepared embossingcylinder is continuously rotated in one direction so that the outerlayer of the sparkling foil paper contacts the prepared embossingcylinder.

In other general aspects, a fabric laminate apparatus includes: anadhesive base paper, and a fabric to which the adhesive base paper ispressed. The adhesive base paper includes: sparkling foil paperincluding an outer layer and a design layer including a plurality oftwo-dimensional geometric forms; and adhesive distributed as a pluralityof separable and identifiable adhesive pieces over the outer layer ofthe sparkling foil paper such that the distribution of pieces has adensity on the order of 15-25 pieces per centimeter squared (pcs/cm2)and a size of a piece is less than 1 millimeter (mm). The size of thelargest adhesive pieces is less than the size of the geometric forms inthe design layer and the density of the distribution of pieces is lessthan a density of the geometric forms in the design layer. Thedistributed adhesive is between the fabric and the sparkling foil paperand the fabric and adhesive base paper are held together by thedistributed adhesive.

Implementations can include one or more of the following features. Forexample, the size of the geometric forms in the design layer can beabout 1.5 mm and the density of the geometric forms in the design layercan be about 70-80 pcs/cm².

The outer layer can be an aluminum plating layer that covers the designlayer. The sparkling foil paper further can include a cover layeropposite the outer layer and a releasing layer between the cover layerand the design layer. The cover layer can be made of polyethyleneterephthalate.

The fabric can be a satin or a tricot.

The apparatus lacks glitter.

The adhesive distributed as the plurality of separable and identifiableadhesive pieces over the outer layer of the sparkling foil paper can bea single monolithic layer.

The adhesive distribution can cover about 25-35% of the outer layer ofthe sparkling foil paper.

The geometric forms in the design layer can have a plurality ofdifferent colors.

The distribution of adhesive pieces on the sparkling foil paper caninclude a distribution of at least three different sizes of pieces asfollows: a plurality of small-sized pieces, distributed in accordancewith a highest density; a plurality of medium-sized pieces, distributedin accordance with a middle density; and a plurality of large-sizedpieces, distributed in accordance with a lowest density. The highestdensity of the small-sized pieces can be about 9-12 pcs/cm²; the middledensity of the medium-sized pieces can be about 8-9 pcs/cm²; and thelowest density of the large-sized pieces can be about 3-5 pcs/cm². Thelarge-sized adhesive pieces on the sparkling foil paper can have ageometric shape in the plane of the sparkling foil paper that isdistinct from a geometric shape of at least the small-sized pieces andthe medium-sized pieces.

At least some of the adhesive pieces in the distribution of adhesivepieces on the sparkling foil paper can have a geometric shape in theplane of the sparkling foil paper that is distinct from a geometricshape of the other pieces in the distribution of pieces on the sparklingfoil paper. The adhesive pieces can lack separable and identifiablereflective particles. The geometric form can be or include one or moreof a circle, a dot, and a polygon (such as a hexagon, square, orpentagon).

In other general aspects, a sparkling fabric includes: a fabricsubstrate; and a tri-layer adhered to the fabric substrate. Thetri-layer includes: an adhesive layer that adheres the tri-layer to thefabric substrate; an exposed design layer; and a metal plating layerbetween the exposed design layer and the adhesive layer. The tri-layeris distributed as a plurality of separable and identifiable tri-layerpieces across the fabric substrate such that the distribution oftri-layer pieces has a density on the order of 15-25 pieces percentimeter squared (pcs/cm²) and a size of a piece is less than 1millimeter (mm).

Implementations can include one or more of the following features. Forexample, the fabric substrate can extend along a plane, the thickness ofthe tri-layer along a direction perpendicular to the plane can be lessthan 10 μm. The thickness of the exposed design layer can be less than 5μm and the thickness of the metal plating layer can be less than 5 μm.The thickness of the tri-layer at each location on the plane can remainsubstantially within a range of acceptable thickness values, the rangebeing less than 1 μm.

The fabric substrate can be a satin or a tricot.

The metal plating layer can include a layer of aluminum having a luster.

The sparkling fabric lacks glitter.

The distribution of the tri-layer can cover about 25-35% of the fabricsubstrate. The distribution of the tri-layer can include a distributionof at least three different sizes of tri-layer pieces as follows: aplurality of small-sized tri-layer pieces, distributed in accordancewith a highest density; a plurality of medium-sized tri-layer pieces,distributed in accordance with a middle density; and a plurality oflarge-sized tri-layer pieces, distributed in accordance with a lowestdensity. The highest density of the small-sized tri-layer pieces can beabout 9-12 pcs/cm²; the middle density of the medium-sized tri-layerpieces can be about 8-9 pcs/cm²; and the lowest density of thelarge-sized tri-layer pieces can be about 3-5 pcs/cm². The large-sizedtri-layer pieces can have a geometric shape in the plane of the fabricsubstrate that is distinct from a geometric shape of at least thesmall-sized tri-layer pieces and the medium-sized tri-layer pieces.

The sparkling fabric that is made herein appears shiny and sparkling,and can be used for garments for fashion dolls, for example. Thesparkling fabric has an appearance of glitter but lacks any glitter.Because glitter is not used in the creation or manufacturing of thesparkling fabric, the texture is more appealing and smooth and thesparkling fabric does not suffer from loss or removal of glitter fromthe fabric substrate during playing or transportation. Moreover, theresulting sparkling fabric can be made with a greater variety of sizesof sparkling pieces. Lastly, the sparkling fabric does not suffer fromflammability issues that can be caused by glitter.

DESCRIPTION OF DRAWINGS

FIG. 1 is a schematic diagram of three materials, a fabric substrate, anadhesive material, and a sparkling foil paper, that make up a sparklingfabric that lacks any glitter;

FIGS. 2A and 2C are respective plan views of a first side and a secondside of the fabric substrate of FIG. 1;

FIG. 2B is a plan view of a side wall of the fabric substrate of FIGS.2A and 2C, the side wall extending from the first side to the secondside of the fabric substrate;

FIGS. 3A and 3C are respective plan views of a first side and a secondside of the sparkling foil paper of FIG. 1;

FIG. 3B is a plan view of a side wall of the sparkling foil paper ofFIGS. 3A and 3C, the side wall extending from the first side to thesecond side of the sparkling foil paper;

FIG. 3D is a perspective view of the sparkling foil paper of FIGS.3A-3C, showing an exploded view of each of the distinct layers;

FIGS. 4A and 4C are respective plan views of a first side and a secondside of the sparkling fabric formed by processing the three materials;the fabric substrate, the adhesive material, and the sparkling foilpaper of FIG. 1;

FIG. 4B is a plan view of a side wall of the sparkling fabric of FIGS.4A and 4C, the side wall extending from the first side to the secondside of the sparkling fabric;

FIG. 4D is a plan view of the side wall of the sparkling fabric of FIG.4B, showing view 4D;

FIG. 5 is a schematic illustration of a first procedure performed forforming a fabric laminate apparatus;

FIG. 6 is a schematic illustration of an implementation showing theapplication of the adhesive to the sparkling foil paper by distributinga plurality of separable and identifiable adhesive pieces over an outerlayer of the sparkling foil paper;

FIG. 7 is a schematic illustration of an implementation showing theadhesive base paper being pressed to the fabric substrate to form thefabric laminate apparatus;

FIGS. 8A and 8C are respective plan views of a first side and a secondside of the fabric laminate apparatus formed using the first procedureof FIG. 5;

FIG. 8B is a plan view of a side wall of the fabric laminate apparatusof FIGS. 8A and 8C;

FIG. 9 is a schematic illustration of a second procedure performed onthe fabric laminate apparatus;

FIG. 10 is a perspective view showing a cover layer of the sparking foilpaper being removed from the rest of the fabric laminate apparatus suchthat the distribution of adhesive pieces and the outer layer of thesparkling foil paper to which adhesive pieces have been applied remainattached to the fabric substrate in accordance with the adhesivedistribution to thereby form the sparkling fabric; and

FIG. 11 is a schematic illustration of an example of the adhesive basepaper and a sparkling fabric showing that a distribution of tri-layerpieces in the sparkling fabric is determined by a distribution of theadhesive pieces on the sparkling foil paper.

DETAILED DESCRIPTION

Referring to FIG. 1, three materials, a fabric substrate 100, anadhesive material 110, and a sparkling foil paper 120, are processed toform a sparkling fabric that has a shiny and sparkling appearancewithout including any glitter.

Referring also to FIGS. 2A-2C, the fabric substrate 100 includes a firstside 201 that receives an adhesive base paper (and ultimately includesthe sparkling design in the finished product); and a second side 202opposite the first side 201. The fabric substrate 100 can be made ofsatin or tricot (for example, trilobal tricot). In some implementations,at least one of the first and second sides 201, 202 is shiny or glossyand the other side can is dull (that is, has very little gloss). Thefabric substrate 100 generally extends along a plane (the X₁Y₁ plane inFIGS. 2A-2C, which is based on the X₁Y₁Z₁ coordinate system associatedwith the fabric substrate 100) and has a thickness (taken along adirection such as the Z₁ direction in FIGS. 2A-2C perpendicular to theplane) that is much smaller than the extent of the plane.

The adhesive material 110 is any substance (typically non-metallic) thatis capable of bonding particles pulled from the sparkling foil paper 120to the fabric substrate 100. The adhesive material 110 is in a liquidstate when first applied in the process (as discussed below) and becomesa solid state after further curing, drying, or hardening. The adhesivematerial can be an organic substance and either naturally occurring andsynthetic.

In some implementations, the adhesive material 110 is synthetic and ismade of one or more polymers. In some implementations, the adhesivematerial 110 includes an adhesive polymer, butanone, and a curing agent.For example, the adhesive material 110 can be made of 50% polymer, 40%butanone, and 10% curing agent, by weight.

Referring also to FIGS. 3A-3D, the sparkling foil paper 120 includes afirst side 321 that receives the adhesive material 110 (and ultimatelyis the side that faces the fabric substrate 100 in the finishedproduct); and a second side 322 opposite the first side 321. Thesparkling foil paper 120 generally extends along a plane (for example,the X₂Y₂ plane in FIGS. 3A-3D, which is in the X₂Y₂Z₂ coordinate systemfixed to the sparkling foil paper 120) and has a thickness (taken alonga direction such as the Z₂ direction in FIGS. 3A-3D perpendicular to theplane) that is much smaller than the extent of the plane. The overallthickness of the sparkling foil paper 120 can be in a range of about30-40 μm.

As shown in FIG. 3D, the sparkling foil paper 120 includes a pluralityof distinct layers. Specifically, the sparkling foil paper 120 includesan outer layer 325 at the first side 321, a design layer 326 adjacentthe outer layer 325, a releasing layer 327 adjacent the design layer326, and a cover layer 328 adjacent the releasing layer 327.

The outer layer 325 can be a metal plating layer that provides ametallic luster. The metal plating layer can be an aluminum platinglayer. The outer layer 325 can have a thickness (taken along the Z₂direction) of about 2-4 (for example, 3) μm.

The design layer 326 includes a plurality of two-dimensional geometricforms (for example, circles, dots, or polygons such as hexagons). Asshown in FIG. 3A, the geometric forms are generally circles or dots andone of these circles 329 is labeled. The geometric forms can beoverlapping (as shown in FIG. 3A), or non-overlapping. The density ofthe geometric forms (taken along the X₂Y₂ plane) and the size or extentof the geometric forms (taken along the X₂Y₂ plane) can be selected toensure that the final sparkling fabric has a desired sparkle effect. Insome implementations, the size or extent of the geometric form is on theorder of millimeters (mm), for example, 1-3 mm or 1.5 mm. In someimplementations, the density of the geometric forms is between about60-90 pieces (pcs) per centimeter squared (cm²) or about 70-80 pcs/cm².The design layer 326 can be an embossed layer, in which the geometricforms are raised in relief from a base surface. In some implementations,the geometric forms can have different colors (for example, some of thegeometric forms can be a first color, while some of the geometric formscan be a second color). The design layer 326 can have a thickness (takenalong the Z₂ direction) of about 2-5 μm.

The plurality of geometric forms of the design layer 326 can create athree-dimensional effect such as an appearance of a hologram. The designlayer 326 can have a metallic luster and also have a gold color. Theshape of the geometric forms can be irregular across the design layer326, such as upon close inspection using a microscope. Thus, some of thegeometric forms can have a first shape such as a circle while others inthe same design layer 326 can be polygons.

The plurality of geometric forms of the design layer 326 can be arepeating pattern that includes a plurality of sub-designs that repeatacross the extent of the design layer 326. For example, a sub-design canhave an area of about 30×25 centimeters (cm) and include different sizedtwo-dimensional geometric forms, such as about 800 largest-sized dots;about 1,000 middle-sized dots; and about 8,000 smallest-sized dots. Asanother example, a sub-design can have an area of about 30×25centimeters (cm) and include different sized two-dimensional geometricforms, such as about 1,000 largest-sized dots; about 1,200 middle-sizeddots; and about 12,000 smallest-sized dots.

The releasing layer 327 is any material or substance that enable theseparation of the cover layer 328 from the design layer 326 during theprocess that forms the sparkling fabric.

The cover layer 328 provides a support for applying the adhesive 110 andthen joining with the fabric substrate 100. Moreover, the cover layer328 is removed from the design layer 326 during the process that formsthe sparkling fabric. In some implementations, the cover layer 328 ismade of polyethylene terephthalate (PET).

Referring to FIGS. 4A-4D, a sparkling fabric 430 is formed by processingthe three materials; the fabric substrate 100, the adhesive material110, and the sparkling foil paper 120. The sparkling fabric 430 includesthe fabric substrate 100 and a tri-layer 440 adhered to the fabricsubstrate 100. The tri-layer 440 is made of an adhesive layer 411 thatadheres the tri-layer 440 to the fabric substrate 100, an exposed designlayer 441, and an outer layer 442 between the exposed design layer 441and the adhesive layer 411. The tri-layer 440 is distributed as aplurality of separable and identifiable tri-layer pieces 443 across thefirst side 201 of the fabric substrate 100. Each tri-layer piece 443therefore includes a piece of adhesive 110 upon which a piece of theouter layer 325 and a piece of the design layer 326 is formed.Therefore, the outer layer 442 is made up of the pieces of the outerlayer 325 and the exposed design layer 441 is made up of the pieces ofthe design layer 326. And, the geometry, size, density, and distributionof these pieces is determined by how the adhesive 110 is applied duringthe process to form the adhesive layer 441, as discussed in detailbelow.

The distribution of the tri-layer pieces 443 across the first side 201(and along the plane X₁Y₁ of the fabric substrate 100) can have adensity on the order of 15-25 pcs/cm². Moreover, each tri-layer piece443 has a shape that corresponds to a shape of the adhesive 110 in theadhesive layer 411. Thus, if the adhesive 110 pieces applied during theprocess are circular in form, then the tri-layer piece 443 will beapproximately circular in form. The size or extent D of a tri-layerpiece 443 (taken along the plane X₁Y₁ of the fabric substrate 100) canbe less than 1 mm.

The thickness T of the tri-layer 440 taken along a directionperpendicular to the X₁Y₁ plane can be less than 10 μm. Moreover, thethickness T of the tri-layer 440 at each location on the X₁Y₁ plane ofthe first side 201 remains relatively constant; that is, it remainswithin an acceptable range of thicknesses. For example, such a range canbe less than 1 μm, less than 0.5 μm, or less than 0.1 μm. The thicknessof the exposed design layer 441 can be less than 5 μm and the thicknessof the outer layer 442 can be less than 5 μm, taken along the directionperpendicular to the X₁Y₁ plane.

Importantly, the sparkling fabric 430 lacks glitter in that glitter isnot used during any step of the process to form the sparkling fabric 430and glitter is not present in the sparkling fabric 430.

Referring to FIG. 5, a first procedure 550 is performed for forming afabric laminate apparatus 575. Initially in the first procedure 550 theadhesive 110 is applied to the sparkling foil paper 120 to form anadhesive base paper 552. Referring also to FIG. 6, the adhesive 110 isapplied to the sparkling foil paper 120 by distributing the adhesive 110as a plurality of separable and identifiable adhesive pieces 616 overthe outer layer 325 of the sparkling foil paper 120. The distribution ofthe pieces 616 has a density on the order of 15-25 pieces per centimetersquared (pcs/cm2) and a size of a piece is less than 1 millimeter (mm)(taken along the X₄Y₄ plane of the adhesive base paper 552). Theadhesive 110 can be distributed such that the pieces 616 cover about25-35% of the area of the outer layer 325 of the sparkling foil paper120.

The distribution of the adhesive pieces 616 on the sparkling foil paper120 can include a distribution of at least three different sizes ofpieces 616 as follows. The distribution can include a plurality ofsmall-sized pieces 616S and these small-sized pieces 616S can bedistributed in accordance with a highest density across the sparklingfoil paper 120. The distribution can include a plurality of medium-sizedpieces 616M, which can be distributed in accordance with a middledensity across the sparkling foil paper 120. The distribution caninclude a plurality of large-sized pieces 616L, which can be distributedin accordance with a lowest density across the sparkling foil paper 120.The highest density of the small-sized pieces 616S is, for example,about 9-12 pcs/cm2; the middle density of the medium-sized pieces 616Mis, for example, about 8-9 pcs/cm2; and the lowest density of thelarge-sized pieces 616L is, for example, about 3-5 pcs/cm2.

The large-sized adhesive pieces 616L on the sparkling foil paper 120 canhave a geometric shape in the plane X₄Y₄ of the sparkling foil paper 120that is distinct from a geometric shape of at least the small-sizedpieces 616S and the medium-sized pieces 616M. For example, some pieces616 can be circles or dots and others can be polygons (such ashexagons). To put it another way, at least some of the adhesive pieces616 in the distribution of adhesive pieces on the sparkling foil paper120 have a geometric shape in the plane of the sparkling foil paper thatis distinct from a geometric shape of the other pieces in thedistribution of pieces on the sparkling foil paper.

The adhesive pieces 616 lack glitter (that is, separable andidentifiable reflective particles).

The adhesive 110 can be applied to the sparkling foil paper 120 to formthe adhesive base paper 525 by applying the adhesive 110 to an embossingcylinder having a surface topography that is correlated with thedistribution of adhesive 110 that is applied to the outer layer 325 ofthe sparkling foil paper 120 to form a prepared embossing cylinder 517.The sparkling foil paper 120 is pressed to the prepared embossingcylinder 517 as the prepared embossing cylinder 517 is continuouslyrotated in one direction so that the outer layer 325 of the sparklingfoil paper 120 contacts the prepared embossing cylinder 517.

Next, and with reference also to FIG. 7, the adhesive base paper 552 ispressed to the fabric substrate 100 to form a fabric laminate apparatus575. The adhesive base paper 552 is pressed to the fabric substrate 100by contacting a side 553 of the adhesive base paper 552 to which theadhesive 110 (in the form of pieces 616) has been applied with or to thefabric substrate 100 while maintaining the temperature of the adhesive110 above a melting point of the adhesive 110. For example, thetemperature of the adhesive 110 can be maintained above or heated aboveabout 140-170° C. while the adhesive base paper 552 is being pressed tothe fabric substrate 100.

The fabric laminate apparatus 575 is cooled until the adhesive 110 (inthe pieces 616) dries. The fabric laminate apparatus 575 can be cooleduntil the adhesive 110 (in the pieces 616) dries by storing the fabriclaminate apparatus 575 in at a temperature-controlled environment ofabout 60° C. to 80° C. for at least 12 hours (for example, for 24hours).

Referring also to FIGS. 8A-8C, the fabric laminate apparatus 575therefore includes the adhesive base paper 552 and the fabric substrate100. The adhesive base paper 552 includes the sparkling foil paper 120having the outer layer 325 and the design layer 326 including theplurality of geometric forms 329. Moreover, the adhesive 110 isdistributed as the plurality of separable and identifiable adhesivepieces 616 over the outer layer 325 of the sparkling foil paper 120 suchthat the distribution of the piece 616 is on the order of 15-25 pcs/cm²and the size of each piece 616 is less than 1 mm. The size of thelargest adhesive pieces 616 is less than the size of the geometric forms329 in the design layer 326 and the density of the distribution ofpieces 616 is less than a density of the geometric forms 329 in thedesign layer 326. The adhesive base paper 552 is pressed to the fabricsubstrate 100 such that the distributed adhesive pieces 616 are betweenthe fabric substrate 100 and the sparkling foil paper 120 and the fabricsubstrate 100 and the adhesive base paper 552 are held together by thedistributed adhesive pieces 616.

The adhesive 110 is distributed as the plurality of pieces 616 over theouter layer 325 of the sparkling foil paper 120 in a single monolithiclayer.

Referring to FIG. 9, a second procedure 960 is performed on the fabriclaminate apparatus 575. Referring also to FIG. 10, the cover layer 328of the sparking foil paper 120 is removed from the rest of the fabriclaminate apparatus 575 such that the distribution of adhesive pieces 616and the outer layer 325 of the sparkling foil paper 120 to whichadhesive pieces 616 have been applied remain attached to the fabricsubstrate 100 in accordance with the adhesive distribution to therebyform the sparkling fabric 430. The portion 1070 of the sparkling foilpaper 120 that lacks adhesive pieces 616 is removed from the rest of thefabric laminate apparatus 575 when the cover layer 328 is removedbecause these portions are not adhered to the fabric substrate 100.

The second procedure 960 can also include maintaining the temperature ofthe environment of the adhesive base paper 552 and the fabric substrate100 while pressing the adhesive base paper 552 to the fabric substrate100, and this temperature can be maintained above 140° C.

Referring again to FIGS. 4A-4D, the sparkling fabric 430 that resultsfrom the first and second procedures 550, 960, respectively, has certaincharacteristics. The distribution of the tri-layer pieces 443 (in thetri-layer 440) covers about 25-35% of the fabric substrate 100.Moreover, the distribution of the tri-layer pieces 443 is directlydetermined by the distribution of the adhesive pieces 616 on thesparkling foil paper 120, as shown in FIG. 11.

The distribution of the tri-layer pieces 443 includes a distribution ofat least three different sizes of tri-layer pieces as follows. Thedistribution includes a plurality of small-sized tri-layer pieces 443S,distributed in accordance with a highest density; a plurality ofmedium-sized tri-layer pieces 443M, distributed in accordance with amiddle density; and a plurality of large-sized tri-layer pieces 443L,distributed in accordance with a lowest density. The highest density ofthe small-sized tri-layer pieces 443S is, for example, about 9-12pcs/cm2; the middle density of the medium-sized tri-layer pieces 443Mis, for example, about 8-9 pcs/cm2; and the lowest density of thelarge-sized tri-layer pieces 443L is, for example, about 3-5 pcs/cm2.

The large-sized tri-layer pieces 443L can have a geometric shape in theplane of the fabric substrate that is distinct from a geometric shape ofat least the small-sized tri-layer pieces 443S and the medium-sizedtri-layer pieces 443M.

What is claimed is:
 1. A fabric printing method comprising: applyingadhesive to a sparkling foil paper to form an adhesive base paper,wherein applying the adhesive to the sparkling foil paper comprisesdistributing the adhesive as a plurality of separable and identifiableadhesive pieces over an outer layer of the sparkling foil paper suchthat the distribution of pieces has a density on the order of 15-25pieces per centimeter squared (pcs/cm²) and a size of a piece is lessthan 1 millimeter (mm); pressing the adhesive base paper to a fabric toform a fabric laminate, wherein pressing the adhesive base paper to thefabric comprises contacting the side of the adhesive base paper to whichthe adhesive has been applied with the fabric while maintaining thetemperature of the adhesive above a melting point of the adhesive;cooling the fabric laminate until the adhesive dries; and removing thesparking foil paper from the fabric of the fabric laminate such that thedistribution of adhesive and the outer layer of the sparkling foil paperto which adhesive has been applied remain attached to the fabric inaccordance with the adhesive distribution to thereby form a sparklingfabric.
 2. The method of claim 1, further comprising maintaining thetemperature of the environment of the adhesive base paper and the fabricwhile pressing the adhesive base paper to the fabric comprisesmaintaining the temperature above 140° C.
 3. The method of claim 1,wherein cooling the fabric laminate until the adhesive dries comprisesstoring the fabric laminate in at a temperature of about 60° C. to 80°C. environment for at least 12 hours.
 4. The method of claim 1, whereinapplying adhesive to the sparkling foil paper to form the adhesive basepaper comprises applying the adhesive so that the adhesive covers about30% of the outer layer of the sparkling foil paper.
 5. The method ofclaim 1, wherein the fabric printing method lacks the application ofglitter to the fabric.
 6. The method of claim 1, wherein applying theadhesive to the sparkling foil paper comprises distributing theplurality of separable and identifiable adhesive pieces as a singlelayer over the outer layer of the sparkling foil paper.
 7. The method ofclaim 1, wherein applying the adhesive to the sparkling foil paper toform the adhesive base paper comprises: applying the adhesive to anembossing cylinder having a surface topography that is correlated withthe distribution of adhesive that is applied to the outer layer of thesparkling foil paper to form a prepared embossing cylinder; and pressingthe sparkling foil paper to the prepared embossing cylinder as theprepared embossing cylinder is continuously rotated in one direction sothat the outer layer of the sparkling foil paper contacts the preparedembossing cylinder.
 8. A fabric laminate comprising: an adhesive basepaper comprising: sparkling foil paper including an outer layer and adesign layer including a plurality of two-dimensional geometric forms;and adhesive distributed as a plurality of separable and identifiableadhesive pieces over the outer layer of the sparkling foil paper suchthat the distribution of pieces has a density on the order of 15-25pieces per centimeter squared (pcs/cm²) and a size of a piece is lessthan 1 millimeter (mm); wherein the size of the largest adhesive piecesis less than the size of the geometric forms in the design layer and thedensity of the distribution of pieces is less than a density of thegeometric forms in the design layer; and a fabric to which the adhesivebase paper is pressed such that the distributed adhesive is between thefabric and the sparkling foil paper and the fabric and adhesive basepaper are held together by the distributed adhesive.
 9. The fabriclaminate of claim 8, wherein the adhesive is made of 50% adhesive, 40%butanone, and 10% curing agent, by weight.
 10. The fabric laminate ofclaim 8, wherein the size of the geometric forms in the design layer isabout 1.5 mm and the density of the geometric forms in the design layeris about 70-80 pcs/cm².
 11. The fabric laminate of claim 8, wherein theouter layer is an aluminum plating layer that covers the design layer.12. The fabric laminate of claim 11, wherein the sparkling foil paperfurther comprises a cover layer opposite the outer layer and a releasinglayer between the cover layer and the design layer.
 13. The fabriclaminate of claim 12, wherein the cover layer is made of polyethyleneterephthalate.
 14. The fabric laminate of claim 8, wherein the fabriclaminate lacks glitter.
 15. The fabric laminate of claim 8, wherein theadhesive distributed as the plurality of separable and identifiableadhesive pieces over the outer layer of the sparkling foil paper is asingle monolithic layer.
 16. The fabric laminate of claim 8, wherein thegeometric forms in the design layer have a plurality of differentcolors.
 17. The fabric laminate of claim 8, wherein the distribution ofadhesive pieces on the sparkling foil paper includes a distribution ofat least three different sizes of pieces as follows: a plurality ofsmall-sized pieces, distributed in accordance with a highest density; aplurality of medium-sized pieces, distributed in accordance with amiddle density; and a plurality of large-sized pieces, distributed inaccordance with a lowest density.
 18. The fabric laminate of claim 17,wherein: the highest density of the small-sized pieces is about 9-12pcs/cm²; the middle density of the medium-sized pieces is about 8-9pcs/cm²; and the lowest density of the large-sized pieces is about 3-5pcs/cm².
 19. The fabric laminate of claim 8, wherein at least some ofthe adhesive pieces in the distribution of adhesive pieces on thesparkling foil paper have a geometric shape in the plane of thesparkling foil paper that is distinct from a geometric shape of theother pieces in the distribution of pieces on the sparkling foil paper.20. The fabric laminate of claim 8, wherein the adhesive pieces lackseparable and identifiable reflective particles.
 21. The fabric laminateof claim 8, wherein the geometric form is a circle, dot, or polygon.